Abstract: A foam twin-sheet formed air filled gasket is provided. The foam sheets need not be covered with one or more layers of air impermeable materials before, during or after the twin-sheet forming process. Methods for manufacturing the air filled gaskets are also disclosed.

Abstract: A duct is shaped and sized for connectability to a vent (or vent adaptor). The duct has an end portion with a flared section separated from a tapered flap section by a lip. The flaps are foldable inwardly at the lip upon engagement with the vent, and airflow through the duct presses the folded flaps against the vent for additional securement of the connection between same. Additional securement and stability may be provided by an adhesive retaining a tapered flap section to a flared section following inward folding of the tapered flap section.

Abstract: A foam duct is provided. Among other applications, it may be used in automotive HVAC systems. The method of making this duct reduces material waste and provides an unexpectedly reliable joint in a duct at a sharp or rounded corner. In place, the airflow further supports the joint. In the method, a first portion of a hollow pre-duct is joined with a second portion of a hollow pre-duct by bending the portions at a cut-out positioned between the portions. The bending is complete when the portions form a mechanical connection, which may be signaled by tactile or audible feedback.

Abstract: A foam duct is provided. Among other applications, it may be used in automotive HVAC systems. The method of making this duct reduces material waste and provides an unexpectedly reliable joint in a duct at a sharp or rounded corner. In place, the airflow further supports the joint. In the method, a first portion of a hollow pre-duct is joined with a second portion of a hollow pre-duct by bending the portions at a cut-out positioned between the portions. The bending is complete when the portions form a mechanical connection, which may be signaled by tactile or audible feedback.

Abstract: A duct is shaped and sized for connectability to a vent (or vent adaptor). The duct has an end portion with a flared section separated from a tapered flap section by a lip. The flaps are foldable inwardly at the lip upon engagement with the vent, and airflow through the duct presses the folded flaps against the vent for additional securement of the connection between same. Additional securement and stability may be provided by an adhesive retaining a tapered flap section to a flared section following inward folding of the tapered flap section.

Abstract: The disclosure provides a hollow foam duct with an insert for improved connectability. The insert provides tactile and/or audible feedback to a user connecting a foam duct to, for example, an HVAC unit in an automobile. A method for making a foam duct is also disclosed.

Abstract: A foam twin-sheet formed air filled gasket is provided. The foam sheets need not be covered with one or more layers of air impermeable materials before, during or after the twin-sheet forming process. Methods for manufacturing the air filled gaskets are also disclosed.

Abstract: A foam air duct for transferring heated or cooled air throughout an automotive vehicle. Material for the foam air duct may be a closed-cell polyolefin foam blend that creates several advantages in automotive HVAC design including reduction in the weight of the foam air duct, flexibility, and reduction in noise, vibrations and harshness (NVH) during operation.